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0116743en 002
0604

Roller

RD 7H

REPAIR MANUAL

0 1 1 6 7 4 3 E N
RD 7H Repair Table of Contents
1. Foreword 5

2. Safety Information 6

2.1 Laws Pertaining to Spark Arresters ...................................................... 6


2.2 Operating Safety .................................................................................. 7
2.3 Operator Safety while using Internal Combustion Engines .................. 8
2.4 Service Safety ...................................................................................... 9
2.5 Label Locations .................................................................................. 10
2.6 Safety and Informational Labels ......................................................... 11

3. Technical Data 16

3.1 Engine ................................................................................................ 16


3.2 Roller .................................................................................................. 17
3.3 Sound and Vibration Measurements .................................................. 17

4. Operation 18

4.1 Controls and Service Locations .......................................................... 18


4.2 Before Starting ................................................................................... 20
4.3 Engine Throttle Control ...................................................................... 20
4.4 Starting the Machine (RD 7H, RD 7H-S) ............................................ 21
4.5 Starting the Machine (RD 7H-ES) ...................................................... 22
4.6 Cold Weather Starting (RD 7H, RD 7H-S) ......................................... 23
4.7 Engine Speed ..................................................................................... 24
4.8 Stopping the Machine (RD 7H, RD 7H-S) .......................................... 24
4.9 Stopping the Machine (RD 7H-ES) .................................................... 24
4.10 Direction and Speed Control .............................................................. 25
4.11 Exciter ................................................................................................ 25
4.12 Back-Up Stop Pad .............................................................................. 26
4.13 Engine Crank ...................................................................................... 26
4.14 Parking Brake ..................................................................................... 27
4.15 Watering System ................................................................................ 27
4.16 Operation on Slopes ........................................................................... 28
4.17 Rollovers ............................................................................................ 28

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Table of Contents RD 7H Repair
5. Maintenance 29

5.1 Maintenance Schedule ........................................................................29


5.2 Engine Oil System ...............................................................................30
5.3 Changing Engine Oil and Oil Filter ......................................................31
5.4 Fuel System ........................................................................................32
5.5 Engine Air Filter ...................................................................................34
5.6 Checking and Adjusting Valve Clearances .........................................35
5.7 Engine Cooling System .......................................................................36
5.8 Scraper Bars .......................................................................................37
5.9 Hydraulic Oil Requirements .................................................................38
5.10 Hydraulic Oil Level ..............................................................................38
5.11 Changing Hydraulic Fluid and Filter ....................................................39
5.12 Direction Lever Adjustment .................................................................40
5.13 Pressure Washing the Machine ..........................................................41
5.14 Storing the Machine ............................................................................41
5.15 Hoisting ...............................................................................................42
5.16 Transporting ........................................................................................43
5.17 Hydraulic Schematic ............................................................................44
5.18 Hydraulic Diagram .............................................................................45
5.19 Electrical Schematic (RD 7H-ES) ........................................................46
5.20 Troubleshooting ...................................................................................48

6. General 49

6.1 Tools ....................................................................................................49


6.2 Reference Numbers ( ) ........................................................................49
6.3 Ordering Parts .....................................................................................49
6.4 Repair Accessories .............................................................................49

7. Hydraulic System 50

7.1 General Description .............................................................................50


7.2 Vibration ..............................................................................................50
7.3 Hydraulic Manifold Block .....................................................................51
7.4 Drive Circuit .........................................................................................52
7.5 Return Line Filter .................................................................................52
7.6 Bleeding the Hydraulic System ...........................................................53
7.7 Hydraulic Diagram ...............................................................................54

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RD 7H Repair Table of Contents
7.8 Hydraulic Schematic ........................................................................... 55
7.9 Test Hydraulic Pressures ................................................................... 56
7.10 Check Vibration Circuit ....................................................................... 56
7.11 Checking Drive Circuit ........................................................................ 58
7.12 Relief Valves ...................................................................................... 60
7.13 Troubleshooting Vibration System ..................................................... 61
7.14 Troubleshooting Drive System ........................................................... 62

8. Power Take-Off 64

8.1 Description ......................................................................................... 64


8.2 Pump Assembly ................................................................................. 65
8.3 Drive Pump ......................................................................................... 66
8.4 Exciter Pump ...................................................................................... 68
8.5 Engine ................................................................................................ 70

9. Roller 73

9.1 Drum - Description ............................................................................. 73


9.2 Drum ................................................................................................... 74
9.3 Drum Assembly .................................................................................. 76
9.4 Exciter ................................................................................................ 78
9.5 Exciter Assembly ................................................................................ 81
9.6 Throttle Cable ..................................................................................... 83
9.7 Direction Cable ................................................................................... 84
9.8 Direction Control Lever ....................................................................... 86

10. Troubleshooting 88

10.1 General ............................................................................................... 88


10.2 Vibration System ................................................................................ 88
10.3 Drive System ...................................................................................... 89
10.4 Starting System .................................................................................. 90

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Table of Contents RD 7H Repair

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RD 7H Repair Foreword
1. Foreword

This manual covers machines with Item Number:


0008042, 0009408, 0009487

Operating / Parts Information

You must be familiar with the operation of this machine before you
attempt to troubleshoot or make any repairs to it. Basic operating and
maintenance procedures are described in the operator’s / parts
manual supplied with the machine. The operator’s / parts manual
should be kept with the machine. Use it to order replacement parts
when needed. If this manual becomes lost, please contact Wacker
Corporation to order a replacement.

Damage caused by misuse or neglect of the unit should be brought to


the attention of the operator, to prevent similar occurrences from
happening in the future.

This manual provides information and procedures to safely repair and


maintain the above Wacker model(s). For your own safety and
protection from injury, carefully read, understand, and observe all
instructions described in this manual. THE INFORMATION
CONTAINED IN THIS MANUAL IS BASED ON MACHINES
MANUFACTURED UP TO THE TIME OF PUBLICATION. WACKER
CORPORATION RESERVES THE RIGHT TO CHANGE ANY
PORTION OF THIS INFORMATION WITHOUT NOTICE.

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Safety Information RD 7 /...
2. Safety Information
This manual contains DANGER, WARNING, CAUTION, and NOTE
callouts which must be followed to reduce the possibility of personal
injury, damage to the equipment, or improper service.

This is the safety alert symbol. It is used to alert you to potential


personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.

DANGER indicates an imminently hazardous situation which, if not


avoided, will result in death or serious injury.
DANGER

WARNING indicates a potentially hazardous situation which, if not


avoided, could result in death or serious injury.
WARNING

CAUTION indicates a potentially hazardous situation which, if not


avoided, may result in minor or moderate injury.
CAUTION

CAUTION: Used without the safety alert symbol, CAUTION indicates


a potentially hazardous situation which, if not avoided, may result in
property damage.
Note: Contains additional information important to a procedure.

2.1 Laws Pertaining to Spark Arresters

Notice: State Health Safety Codes and Public Resources Codes


specify that in certain locations spark arresters be used on internal
combustion engines that use hydrocarbon fuels. A spark arrester is a
device designed to prevent accidental discharge of sparks or flames
from the engine exhaust. Spark arresters are qualified and rated by
the United States Forest Service for this purpose.
In order to comply with local laws regarding spark arresters, consult
the engine distributor or the local Health and Safety Administrator.

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RD 7 /... Safety Information
2.2 Operating Safety

Familiarity and proper training are required for the safe operation of
equipment! Equipment operated improperly or by untrained personnel
can be dangerous! Read the operating instructions contained in both
WARNING this manual and the engine manual and familiarize yourself with the
location and proper use of all controls. Inexperienced operators should
receive instruction from someone familiar with the equipment before
being allowed to operate the machine.

2.2.1 ALWAYS operate machine with all safety devices and guards in place
and in working order.

2.2.2 ALWAYS check that all controls are functioning properly immediately
after start-up! DO NOT operate machine unless all controls operate
correctly.

2.2.3 ALWAYS remain aware of changing surface conditions and use extra
care when operating over uneven ground, on hills, or over soft or
coarse material. The machine could shift or slide unexpectedly.

2.2.4 ALWAYS remain aware of changing positions and movement of other


equipment and personnel on the job site.

2.2.5 ALWAYS use caution when operating near the edges of pits, trenches
or platforms. Check to be sure that ground surface is stable enough to
support the weight of the machine and that there is no danger of the
roller sliding, falling or tipping.

2.2.6 ALWAYS position yourself safely when operating machine in reverse


or on hills. Leave enough space between yourself and the machine so
you will not be placed in a hazardous position should the machine slide
or tip.

2.2.7 ALWAYS operate the machine with both feet on the ground! DO NOT
stand, sit, or ride on machine while in operation.

2.2.8 ALWAYS remain aware of moving parts and keep hands, feet, and
loose clothing away from moving parts of equipment.

2.2.9 NEVER operate with fuel cap loose or missing.

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Safety Information RD 7 /...
2.3 Operator Safety while using Internal Combustion Engines

Internal combustion engines present special hazards during operation


and fueling! Read and follow warning instructions in engine owner’s
DANGER manual and safety guidelines below. Failure to follow warnings and
safety guidelines could result in severe injury or death.

2.3.1 DO NOT run machine indoors or in an enclosed area such as a deep


trench unless adequate ventilation, through such items as exhaust
fans or hoses, is provided. Exhaust gas from the engine contains
poisonous carbon monoxide gas; exposure to carbon monoxide can
cause loss of consciousness and may lead to death.

2.3.2 DO NOT smoke while operating machine.

2.3.3 DO NOT smoke when refueling engine.

2.3.4 DO NOT refuel hot or running engine.

2.3.5 DO NOT refuel engine near open flame.

2.3.6 DO NOT spill fuel when refueling engine.

2.3.7 DO NOT run engine near open flames.

2.3.8 ALWAYS refill fuel tank in well-ventilated area.

2.3.9 ALWAYS replace fuel tank cap after refueling.

2.3.10 DO NOT touch or lean against hot exhaust pipes.

2.3.11 DO NOT mix diesel with any other fluids.

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RD 7 /... Safety Information
2.4 Service Safety

Poorly maintained equipment can become a safety hazard! In order


for the equipment to operate safely and properly over a long period of
time, periodic maintenance and occasional repairs are necessary.
WARNING

2.4.1 DO NOT modify the equipment without express written approval of the
manufacturer.

2.4.2 DO NOT open hydraulic lines or loosen hydraulic connections while


engine is running! Hydraulic fluid under pressure can penetrate the
skin, cause burns, blind, or create other potentially dangerous
hazards. Set all controls in neutral and turn engine off before loosening
hydraulic lines.

2.4.3 ALWAYS check and tighten all external fasteners at regular intervals.

2.4.4 ALWAYS keep area around muffler free of debris such as leaves,
paper, cartons, etc. A hot muffler could ignite them, starting a fire.

2.4.5 ALWAYS keep machine clean and labels legible. Replace all missing
and hard-to-read labels. Labels provide important operating
instructions and warn of dangers and hazards.

2.4.6 ALWAYS replace safety devices and guards after repairs and
maintenance.

2.4.7 ALWAYS turn engine off before performing maintenance or making


repairs.

2.4.8 ALWAYS make sure slings, chains, hooks, ramps, jacks and other
types of lifting devices are attached securely and have enough weight-
bearing capacity to lift or hold the machine safely. Always remain
aware of the position of other people around you when lifting the
machine.

2.4.9 ALWAYS turn engine off before servicing machine. If the engine has
electric start, disconnect negative terminal on battery

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Safety Information RD 7 /...
2.5 Label Locations

O P E R A T O R 'S M A N U A L M U S T B E E L M A N U A L D E O P E R A C IO N D E B E
S T O R E D O N M A C H IN E . S E R R E T E N ID O E N L A M A Q U IN A .
R E P L A C E M E N T O P E R A T O R 'S C O N T A C T E A S U D IS T R IB U ID O R
M A N U A L C A N B E O R D E R E D W A C K E R M A S C E R C A N O P A R A
T H R O U G H Y O U R L O C A L W A C K E R P E D IR U N E J E M P L A R
D IS T R IB U T O R . A D IC IO N A L .
D IE B E T R IE B S V O R S C H R IF T M U S S L A N O T I C E D 'E M P L O I D O I T
A N D E R M A S C H IN E A U F B E W A H R T E T R E M U N IE S U R L A M A C H IN E .
W E R D E N . Z U R B E S T E L L U N G V O N C O N T A C T E R L E D IS T R IB U T E U R
1 1 5 0 9 6

E R S A T Z B Ü C H E R N W E N D E N S IE W A C K E R L E P L U S P R O C H E
S IC H B IT T E A N IH R E N P O U R C O M M A N D E R U N
Ö R T L IC H E N W A C K E R H Ä N D L E R . E X E M P L A IR E S U P P L E M E N T A IR E .

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RD 7 /... Safety Information
2.6 Safety and Informational Labels

Wacker machines use international pictorial labels where needed.


These labels are described below:

Label Meaning
DANGER!
Engines emit carbon monoxide; operate only
in well ventilated area. Read the operator’s
manual.
No sparks, flames or burning objects near
machine. Shut off engine before refueling.

WARNING!
Hot surface!

WARNING!
Read and understand the supplied operator’s
manual before operating this machine. Failure
to do so increases the risk of injury to yourself
or others.

WARNING!
To prevent hearing loss, wear hearing protec-
tion when operating this machine.

Guaranteed sound power level in dB(A).

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Safety Information RD 7 /...
Label Meaning
CAUTION!
Use only clean, filtered diesel fuel.

O P E R A T O R 'S M A N U A L M U S T B E E L M A N U A L D E O P E R A C IO N D E B E
Operator’s Manual must be stored on
S T O R E D O N M A C H IN E . S E R R E T E N ID O E N L A M A Q U IN A .
R E P L A C E M E N T O P E R A T O R 'S C O N T A C T E A S U D IS T R IB U ID O R machine. Replacement Operator’s Manual can
M A N U A L C A N B E O R D E R E D W A C K E R M A S C E R C A N O P A R A
T H R
D IS T
O U G
R IB
H Y O
U T O R
U R
.
L O C A L W A C K E R P E
A D
D IR U
IC IO N
N E J E
A L .
M P L A R be ordered through your local Wacker distribu-
D IE
A N
B E T R IE B S
D E R M A S C
V O R
H IN E
S C H R IF
A U F B E
T M
W A
U S S
H R T
L A
E T R E
N O T IC E D
M U N IE
'E M P
S U R
L O I D O
L A M A
IT
C H IN E .
tor.
W E R D E N . Z U R B E S T E L L U N G V O N C O N T A C T E R L E D IS T R IB U T E U R

1 1 5 0 9 6
E R S A T Z B Ü C H E R N W E N D E N S IE W A C K E R L E P L U S P R O C H E
S IC H B IT T E A N IH R E N P O U R C O M M A N D E R U N
Ö R T L IC H E N W A C K E R H Ä N D L E R . E X E M P L A IR E S U P P L E M E N T A IR E .

Water Control Valve

Vibration Control ON/OFF

No lift point.
(one of two)

CAUTION!
Lifting point

Tie-down point

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RD 7 /... Safety Information
Label Meaning
Engine oil drain.

Hydraulic oil reservoir fill

Hydraulic oil drain

Key switch, engine start:


Off
On
Start

This machine may be covered by one or more


patents.

A nameplate listing the Model Number, Item


Number, Revision, and Serial Number is
attached to each unit. Please record the infor-
mation found on this plate so it will be available
should the nameplate become lost or dam-
aged. When ordering parts or requesting ser-
vice information, you will always be asked to
specify the model, item number, revision num-
ber, and serial number of the unit.

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Safety Information RD 7 /...
Label Meaning

Check engine oil level.


Use SAE10W30.

Check fuel level.

Engage parking brake.

Turn vibration off.

Pull engine throttle out.

Pull decompression lever up.

Insert crank handle.

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RD 7 /... Safety Information
Label Meaning
Rotate crank handle counterclockwise 5X.

Remove crank handle.

Disengage parking brake.

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Technical Data RD 7 /...
3. Technical Data

3.1 Engine

Item No. RD 7H RD 7H-ES RD 7H-S


0008042 0009408 0009487

Engine
Engine Type One cylinder, 4-stroke, air cooled, diesel engine
Engine Make Hatz
Engine Model 1D41S 1D41S VAR I
Rated Power kW (Hp) 4.8 (6.5) @
5.5 (7.5) @ 2800 rpm
2600 rpm
Operating Speed rpm 2630±30
Valve Clearance (cold)
intake: mm (in.) 0.10 (0.004)
exhaust: 0.20–0.25 (0.008–0.010)
Battery V — 12 VDC —
Air Cleaner type Dry pleated paper element
Engine Lubrication oil grade SAE15W40
Engine Oil Capacity l (qt.) 1.2 (1.25)
Fuel type No. 2 Diesel
Fuel Tank Capacity l (gal.) 5.0 (1.3)
Fuel Consumption l (gal.)/
1.67 (0.44)
hr.

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RD 7 /... Technical Data
3.2 Roller

Item No. RD 7H RD 7H-ES RD 7H-S


0008042 0009408 0009487

Roller
Overall Dimensions - Handle mm 1168 x 692 x 2159
up (l x w x h) (in.) (46 x 27.25 x 85)
Overall Dimensions - Handle mm 2654 x 692 x 1270
down (l x w x h) (in.) (104.5 x 27.25 x 50)
Operating Weight kg (lbs.) 650 (1430)
Area Capacity m2 (ft.2)/hr. 2613 (28115)
Forward Speed (max) m (ft.) / min. 66 (220)
Reverse Speed (max) m (ft.) / min. 33 (110)
Vibration Frequency Hz (vpm) 55 (3300)
Hydraulic System Lubrication type SAE 10W30 hydraulic fluid*
Hydraulic System Capacity l (gal.) 30 (8)
Gradeability with vibration % 40
Gradeability without vibration % 25
*See “Hydraulic Oil Requirements”

3.3 Sound and Vibration Measurements

The required sound specification, Paragraph 1.7.4.f of 89/392/EEC


Machinery Directive, is:
the sound pressure level at operator’s location (LpA) = 95 dB(A)
the guaranteed sound power level (LWA) = 108 dB(A).
These sound values were determined according to ISO 3744 for the
sound power level (LWA) and ISO 6081 for the sound pressure level
(LpA) at the operator’s location.
The weighted effective acceleration value, determined according to
ISO 8662 Part 1, is approximately:
Hands = 9.66 m/s2.
The sound and vibration measurements were obtained with the
machine operating on hard asphalt at maximum RPM and top speed.

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Operation RD 7 /...
4. Operation

4.1 Controls and Service Locations

Ref. Description Ref. Description


1. Handle locking pin 15. Crank guide sleeve
2. Tie-down location 16. Fuel tank fill cap
3. Scraper bar (4 total) 17. Top cover
4. Water control valve 18. Hydraulic tank (under front cover)
5. Shockmount (4 total) 19. Hydraulic tank fill port (under top cover)
6. Parking brake 20. Hydraulic tank sightglass (through slots)
7. Back-up stop pad 21. Fuel tank
8. Forward/reverse control lever 22. Front cover
9. Exciter control lever 23. Lifting eye
10. Water tank fill cap 24. Operator’s manual holder
11. Crank storage location 25. Water tank
12. Throttle control 26. Battery
13. Air cleaner indicator 27. Ignition Switch
14. Oil dipstick 28. Alarm
B

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RD 7 /... Operation

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Operation RD 7 /...
4.2 Before Starting

Before starting the machine, check the following:


• Engine oil level
• Air cleaner maintenance indicator
• Fuel level
• Hydraulic fluid level
• Water tank level

4.3 Engine Throttle Control

See Graphic: wc_gr001338


The engine throttle control (c) is pulled out to start the engine. Press
in on the rubber button (c1) with your thumb while pulling the control
out. The control will stay at any position, and can be fine-tuned by
twisting the control in or out.
To stop the engine, push the throttle control all the way in by pressing
on the rubber button with the heel of your hand.

c1
a
c

d
wc_gr001338

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RD 7 /... Operation
4.4 Starting the Machine (RD 7H, RD 7H-S)
See Graphic: wc_gr001338, wc_gr01339, wc_gr001340
4.4.1 Check that the exciter (a) is in the OFF position.
4.4.2 Pull the throttle control (c) up to open engine throttle.
4.4.3 Turn the decompression lever (f) until stop (f1) is reached. In this
position, the automatic decompression system is heard to engage.
4.4.4 Insert the crank (d) into the guide sleeve (b).
4.4.5 Turn the crank 5 turns to build up pressure for the engine to fire.
4.4.6 Stand alongside the engine, facing the back of the machine (e) and
grasp the tubular grip with both hands.
Do not stand in any other position! Injury may result if the engine
should backfire!
WARNING

4.4.7 Turn the handle slowly until the pawl engages the rachet, then
increase the turning force to build up speed.
Note: The highest speed must be reached when the decompression
lever (f) returns to the (f0) position.
4.4.8 As soon as the engine has started, pull the starting handle out of the
guide sleeve.
You must hold the tubular grip firmly to maintain contact all the time
between the starting handle and the engine. Maintain turning force
WARNING during the entire hand starting operation.
Note: If backfiring occurs when starting the engine because the crank
handle was not turned firmly enough, the brief reverse rotation at the
handle tube separates the link between the crank lug and the driving
dog.
4.4.9 If the engine begins to run backwards after backfiring (smoke emerges
from air cleaner), release the crank handle immediately and stop the
engine.
4.4.10 To restart the engine, wait until it has come to a standstill, then repeat
the starting prepartions.
4.4.11 Allow engine to warm up for a few minutes before operating machine.

e
f1

f
f0

wc_gr001339 wc_gr001340

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Operation RD 7 /...
4.5 Starting the Machine (RD 7H-ES)

See Graphic: wc_gr001529

4.5.1 Check that the exciter (a) is in the OFF position.

4.5.2 Pull the throttle control (b) up to open engine throttle.

4.5.3 Turn the ignition switch (c) to start the engine

When the key is in the ON position, an alarm will sound. The alarm is
a reminder to turn the key to the OFF position when the machine is not
CAUTION in use. Failure to do this will result in a dead battery.

Note: The alarm will stop when proper oil pressure is reached.

Do not crank the engine starter for more than 15 seconds at one time.
Longer cranking cycles could lead to starter damage.
WARNING

4.5.4 Allow engine to warm up for a few minutes before operating machine.

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RD 7 /... Operation
4.6 Cold Weather Starting (RD 7H, RD 7H-S)

See Graphic: wc_gr001338, wc_gr01339, wc_gr001340


At temperatures below approximately -5°C (30°F) always turn the
engine over to ensure that it rotates freely.
4.6.1 Check that the exciter (a) is in the OFF position.
4.6.2 Pull the throttle control (c) up to open engine throttle.
4.6.3 Move the decompression lever (f) to a position that is not as far around
as (f1).
4.6.4 Insert the crank (d) into the guide sleeve (b).
4.6.5 Turn the crank 10 turns to build up pressure for the engine to fire.
4.6.6 Clean around the cover of the metering device (g), then:
• remove the cover
• fill with lubricating oil until the level reaches the upper rim
• press the cover on firmly.
Perform filling operation TWICE, then immediately start the engine.
See “Starting the Machine.”

c1
a
c

d
wc_gr001338

e
f1

f
f0

wc_gr001339 wc_gr001340

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Operation RD 7 /...
4.7 Engine Speed

During operation, run the engine at full throttle (2800 rpm). This
ensures maximum exciter speed and will produce the best
compaction.

Should the engine ever speed out of control and for some reason will
WARNING
not kill, pulling up on the decompression lever (f), which could be hot
to the touch, will kill the engine.

4.8 Stopping the Machine (RD 7H, RD 7H-S)

4.8.1 Turn the exciter off, and close the water control valve.

4.8.2 Push the throttle control to the minimum position to stop the engine.

4.8.3 Apply the parking brake.

4.8.4 Clean the scraper bars before putting the roller away.

4.9 Stopping the Machine (RD 7H-ES)

4.9.1 Turn the exciter off, and close the water control valve.

4.9.2 Push the throttle control to the minimum position to stop the engine.

4.9.3 Turn engine switch to “OFF”.

4.9.4 Apply the parking brake.

4.9.5 Clean the scraper bars before putting the roller away.

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RD 7 /... Operation
4.10 Direction and Speed Control

See Graphic: wc_gr001341


Travel direction and speed are controlled by the movable lever (a)
inside the handle. From the neutral position, the handle is pushed
away from the operator to travel forward, and towards the operator to
travel in reverse.
Keep both hands on handle while operating machine. Handle may
pivot rapidly while in operation and cause injury.
WARNING
Speed is varied by the movement of the lever; the farther the lever is
pushed in either direction, the faster the roller will travel in that
direction.
If the linkage separates from the directional lever while the machine is
running, the roller could “run away” and cause injury. In the event of
WARNING this occurring, the throttle (b1) must be pushed in to stop the engine.

b1

wc_gr001341

4.11 Exciter

The exciter provides the vibration and can be used in most applications
involving cohesive-type soils with heavy clay content, as well as loose
soils and gravel.
CAUTION: DO NOT run machine with the vibration on over hard
surfaces like concrete or compacted asphalt. The drum bearings can
be damaged.

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Operation RD 7 /...
4.12 Back-Up Stop Pad

See Graphic: wc_gr001342


A back-up stop pad (a) is mounted to the rear section of the machine
behind the control panel. The back-up stop pad operates in reverse
only.
If the machine backs into an obstruction or if the operator becomes
trapped behind it, the pad will be pressed forward and stop the
machine. The machine can move only in the forward direction when
the handle is brought back through the neutral position.

STOP

wc_gr001342

4.13 Engine Crank

See Graphic: wc_gr001345


The engine crank is equipped with kick-back damping to protect the
operator from injury should the engine backfire. The brief reverse
rotation at the handle tube (a) separates the link between the crank lug
(b) and the driving dog (c).

a b c

wc_gr001345

wc_tx000294gb.fm 26
RD 7 /... Operation
4.14 Parking Brake

See Graphic: wc_gr001343


The parking brake is used to ensure that the machine will not roll when
not in use. It engages the weld stops on the drum, therefore a small
amount of movement is possible before the brake will catch and stop
the machine.
To disengage the parking brake:
Rotate the handle (a) 90° clockwise and bring it to rest in a shallow
detent.
To engage the parking brake:
Rotate the handle (a) 90° counterclockwise and allow it to rest in the
deep detent.
CAUTION: The parking brake is designed to hold the machine on an
incline with the engine off. Do not drive against the parking brake in the
engaged position. The brake may bend and damage the machine.

a wc_gr001343

4.15 Watering System

See Graphic: wc_gr001344


The RD 7 is equipped with a water control valve which allows the roller
to be used wet or dry, and a sprinkler system to distribute the water
evenly across the drums. The water is gravity fed to the sprinklers
when the control valve is in the OPEN (horizontal) position (a).

wc_gr001344

wc_tx000294gb.fm 27
Operation RD 7 /...
4.16 Operation on Slopes

See Graphic: wc_gr001346 and wc_gr001347


When operating on slopes or hills special care must be taken to reduce
the risk of personal injury or damage to the equipment. Always operate
the machine up and down hills rather than from side to side. For safe
operation and for protection of the engine, continuous duty use should
be restricted to slopes of 22° (40% grade) or less.
NEVER operate machine on side slopes. The machine may roll over,
even on stable ground.
WARNING

22˚
40%

wc_gr001346 wc_gr001347

4.17 Rollovers

Proper operation of the machine on slopes will prevent rollovers. Read


and follow Safety instructions in “Operating Safety” and “Operation on
Slopes”. If a machine rollover does occur, care must be taken to
prevent damage to the engine. In this position, oil from the engine
crankcase can flow into the combustion chamber, which can severely
damage the engine next time it is started. If the machine has rolled on
its side, immediate steps should be taken to right the machine.
CAUTION: To prevent damage to the engine after a roll-over, the
machine must NOT be started, AND it must be serviced to remove any
oil that may have been trapped in the combustion chambers. Contact
your local Wacker dealer for instructions or servicing.

wc_tx000294gb.fm 28
RD 7 /... Maintenance
5. Maintenance

5.1 Maintenance Schedule

Daily After Every Every Every


before first 250 500 1200
starting 25 hrs.* hrs. hrs. hrs.

Check engine oil level. •


Check air cleaner maintenance indicator. •
Check the water trap. •
Check hydraulic oil level. •
Clean the scraper bars. •
Check function of back-up stop pad and

direction control lever.
Check tappet clearance. •
Examine screw connections. •
Replace engine oil and filter. • •
Check and adjust valve clearances. •
Clean cooling system. •
Replace fuel filter. •
Clean or replace air filter. •
Change hydraulic system return line filter. •
Check and adjust scraper bars. •
**Check linkage components. •
Clean battery terminals (RD 7H-ES). •
Change hydraulic oil and filter. •
*For new or reconditioned engines.
CAUTION: DO NOT tighten cylinder head fastenings.
** Maintain linkages more frequently in dusty environments. Lubricating linkages is not recom-
mended. However, if necessary, use a dry lubricant that does not attract dust.

wc_tx000295gb.fm 29
Maintenance RD 7 /...
5.2 Engine Oil System

See Graphic: wc_gr001348


Engine oil level
Stop the machine, switch off the engine and apply the parking brake.
Check the oil with the machine standing on a level surface.
5.2.1 Clean around the dipstick.
5.2.2 Check the oil level on the extended dipstick (a). If necessary, top up
to the “max” mark.
Engine may be hot enough to cause burns! Allow engine to cool prior
to servicing.
WARNING

wc_gr001348

wc_tx000295gb.fm 30
RD 7 /... Maintenance
5.3 Changing Engine Oil and Oil Filter

See Graphic: wc_gr001349


Changing engine oil and oil filter
Stop the machine and apply the parking brake.
Change the oil with the machine standing on a level surface.
Run the engine for a few minutes and then stop the engine.
Drain the engine oil when it is still warm.
Danger of burns! Care must be taken when draining hot engine oil.
Hot oil can burn!
WARNING

5.3.1 Unscrew the oil drain plug and allow all the oil to drain into a container
that will hold about 1–1.5 liters (1–1.5 quarts).
5.3.2 Clean the oil drain plug and attach a new seal. Insert and tighten the
plug.
5.3.3 Replace the oil filter element with a new one, inserting it with the “TOP”
mark up.
5.3.4 Check the condition of the O-ring (b) and replace it if necessary.
5.3.5 Wet the O-ring and threads of the screw plug on the oil filter housing
using high temperature grease available from your Hatz dealer.
5.3.6 Add engine oil up to the “MAX” mark on the dipstick, approximately
1.1–1.2 liters (1–1¼ quarts).
5.3.7 Run the engine for a short period, then check the oil level again and
top up if necessary.
5.3.8 Make sure that there is no leakage past the screw plug on the oil filter
housing.

wc_gr001349

wc_tx000295gb.fm 31
Maintenance RD 7 /...
5.4 Fuel System
See Graphic: wc_gr001351
Fuel tank water trap
The interval at which you should check the water trap depends upon
the amount of water in the fuel. The normal interval is one week.
Stop the machine, switch off the engine, and apply the parking brake.
5.4.1 Remove the cover from the roller to allow access to the fuel tank water
trap.
5.4.2 Loosen the hex screw (a) until only 2 threads are holding it in place.
5.4.3 Trap the drops that emerge in a transparent container.
Note: Since water has a higher specific gravity than diesel fuel, the
water emerges first. The two substances separate at a clearly visible
line.
5.4.4 When only diesel fuel emerges, tighten the hex screw.
CAUTION: Diesel fuel destroys shockmounts. Clean fuel spillage
immediately.
Changing the fuel filter cartridge
Fuel filter maintenance intervals depend on the purity of the diesel fuel
used. If your fuel is dirty, perform this operation at 250 hours.
Stop the machine, switch off the engine, and apply the parking brake.
Danger of explosion! Diesel fuel is flammable and must be treated with
the necessary caution. Do not smoke. Avoid sparks and open flames.
WARNING

5.4.5 Remove the cover from the roller to allow access to the fuel filter.
5.4.6 Place a suitable container under the filter to trap escaping fuel.
5.4.7 Close the fuel supply line.
5.4.8 Pull the fuel supply line (a) off the fuel filter trap (b) at both sides, and
insert the new filter.
CAUTION: Keep the area clean to prevent dirt from entering the fuel
lines.
5.4.9 Make sure the filter is oriented with the arrow in the direction of flow.
5.4.10 Open the fuel supply line until fuel begins to flow.
5.4.11 Run the engine briefly to check the fuel filter and lines for leaks.

wc_tx000295gb.fm 32
RD 7 /... Maintenance

a
c

wc_gr001351

d
e

a b c

g f

wc_gr001352

wc_tx000295gb.fm 33
Maintenance RD 7 /...
5.5 Engine Air Filter

See Graphic: wc_gr001352


Checking the air cleaner blockage indicator
5.5.1 Briefly run the engine at full speed. If the rubber bellows is pulled in
and obscures the green zone (a), clean or replace the air filter.
5.5.2 In dusty operating conditions, check the rubber bellows several times
per day.
Cleaning or replacing the engine air filter
Engine may be hot enough to cause burns! Allow engine to cool prior
to servicing.
WARNING

5.5.3 Loosen the wing nut (a) and remove it and the air cleaner cover (b).
Note: The decompression lever will also come off.
5.5.4 Pull out the filter cartridge (a).
5.5.5 Check that the valve plate (b) for the air blockage indicator is clean and
in good condition.
Cleaning dry dirt from the filter cartridge
5.5.6 Blow through the filter cartridge from the inside using a compressed air
gun.
5.5.7 Continue until all dust has been removed.
CAUTION: Only use filtered, dry compressed air. Do not exceed an
air pressure of more than 5 bar (70 psi). Keep the nozzle at a distance
of 150 mm (6 inches) from the element.
Cleaning wet or oily dirt from the filter
5.5.8 Change the filter cartridge.
CAUTION: Always trace and correct the cause of wet or oily
contamination of a filter element.
Checking the filter cartridge
5.5.9 Hold the element up to a light or pass a lamp through the middle to
check the condition of the element folds (c).
5.5.10 Check that the sealing surface (d) is in good condition.
CAUTION: If there is even slight damage to the paper filter element or
the sealing surface, replace the filter cartridge.

wc_tx000295gb.fm 34
RD 7 /... Maintenance
5.6 Checking and Adjusting Valve Clearances

See Graphic: wc_gr001353


Stop the machine, apply the parking brake and switch off the engine.
5.6.1 Make sure that the compression lever is in position “0”. See Starting
the machine.
5.6.2 Remove the cylinder head cover and gasket.
5.6.3 Turn the engine over in the normal direction of rotation until
compression is felt.
5.6.4 Check the inlet valve clearance between the rocker and valve stem
using a feeler gauge (a).
5.6.5 If the valve clearance is incorrect, loosen the hex nut (c).
Note: See Technical Data for valve clearances.
5.6.6 Turn the adjusting screw (b) with a screwdriver until feeler gauge (a)
can just be pulled through between the rocker and the valve stem with
slight resistance to its movement after nut (c) has been retightened.
5.6.7 Repeat adjustment with the outlet valve.
5.6.8 Place a new gasket under the cylinder head cover, replace the cylinder
head, and tighten down uniformly.
5.6.9 Run the engine briefly and make sure that the cover is not leaking.

a b

c
wc_gr001353

wc_tx000295gb.fm 35
Maintenance RD 7 /...
5.7 Engine Cooling System

See Graphic: wc_gr001354

Stop the machine, apply the parking brake and switch off the engine.
The engine must be allowed to cool down before cleaning.

Dry contamination

5.7.1 Clean all air guide elements and the complete cooling air zones (a) on
the cylinder head, cylinder and flywheel blades without making them
wet. Blow them dry with compressed air.

Moist or oily contamination

5.7.2 Clean the complete area with a solvent or cold cleaner according to its
manufacturer’s instructions, then spray down with a high pressure
water jet. Dry with compressed air.

5.7.3 Trace the source of oil leaks causing greasy dirt. Repair the leaks,
seeking advice of your Hatz engine dealer if necessary.

5.7.4 After cleaning, run the engine to dry it out and to prevent the formation
of rust.

wc_gr001354

wc_tx000295gb.fm 36
RD 7 /... Maintenance
5.8 Scraper Bars

See Graphic: wc_gr001355


Check the four scraper bars (a) for wear. Scraper bars are made of
synthetic materials which can wear very quickly when used with
abrasive materials. Replace scraper bars as needed.
Cleaning the scraper bars
The scraper bars should be cleaned daily after use or as often as
needed to remove built-up dirt, mud, and tar.
Use a high-pressure water jet and a strong brush if needed.

a a

a
wc_gr001355

wc_tx000295gb.fm 37
Maintenance RD 7 /...
5.9 Hydraulic Oil Requirements

Wacker recommends the use of a premium grade, petroleum-based


hydraulic oil with anti-wear and anti-foam characteristics. Good anti-
wear oils contain additives to reduce oxidation, prevent foaming, and
provide for good water separation. These oils offer superior motor and
pump life.
When selecting hydraulic fluid for your machine be sure to specify anti-
wear properties. Wacker offers a premium grade hydraulic oil for use
in this machine.
• Wacker Hydraulic Oil - P/N 85094
Avoid mixing different brands and grades of hydraulic fluids.
Oil Viscosity
Most hydraulic oils are available in different viscosities. The SAE
number for an oil is used strictly to identify viscosity. It does not indicate
the type of oil (engine, hydraulic, gear, etc.) The higher the SAE
number, the thicker the oil.
For normal applications use a good non-detergent, anti-wear,
hydraulic oil with a viscosity rating of SAE 10W30.

5.10 Hydraulic Oil Level

See Graphic: wc_gr001356


A hydraulic oil level sightglass (a) is located on the hydraulic tank and
is visible through the slots on the top cover.
Check the oil level with the machine standing on a level surface. The
oil level should be at the halfway mark on the sightglass. If the level is
low, remove the top cover and top up with hydraulic oil as necessary.
If hydraulic oil continually needs to be added, inspect hoses and
connections for possible leaks. Repair hydraulic leaks immediately to
prevent damage to hydraulic components.

wc_gr001356

wc_tx000295gb.fm 38
RD 7 /... Maintenance
5.11 Changing Hydraulic Fluid and Filter
See Graphic: wc_gr001357
Stop the machine, switch off the engine, and apply the parking brake
with the machine standing on a level surface.
5.11.1 Remove the top cover of the roller.
5.11.2 Remove the drain plug (b) from the end of the drain hose that is
attached to the hydraulic tank.
5.11.3 Allow the hydraulic oil to drain into a suitable container.
5.11.4 When all the oil has drained out, reinstall the drain plug back into the
hose and secure in place.
5.11.5 Place a plastic bag around the filter (a) to contain any oil spillage.
5.11.6 Unscrew the old filter.
5.11.7 Install the new filter. Screw the new filter on by hand, making sure that
it is not cross threaded.
CAUTION: Use only original spare parts.
5.11.8 Tighten using both hands.
5.11.9 Fill the hydraulic tank with hydraulic oil until the level is visible halfway
up the sightglass.
5.11.10 Run the engine briefly, then stop the engine and check for leaks.
5.11.11 Check the level in the sightglass, and top up if necessary.
Note: In the interests of environmental protection, place plastic
sheeting and a container under the machine to collect the liquid which
drains off. Dispose of this liquid properly.

wc_tx000295gb.fm 39
Maintenance RD 7 /...
5.12 Direction Lever Adjustment

See Graphic: wc_gr001358


The direction control lever should have a long forward travel and a
short reverse travel. If the lever appears out of adjustment, it can be re-
adjusted as follows:
5.12.1 Disconnect adjustment cable from ball joint (a) and clevis pin (b).
5.12.2 Check adjustment of cable and spring centering device (c). Proper
adjustment allows the same travel when cable is pushed in or pulled
out approximately 25.4 mm (1.00" ).
5.12.3 Reattach the clevis end of the cable to the pump control device.
5.12.4 Use either the thread engagement of the clevis (d) or end of control
arm link (e) to adjust the pump to center position by turning clockwise
or counterclockwise.
5.12.5 Reconnect cable to ball joint (a).
5.12.6 Adjust cable where mounted on handle (f) so that dimension (g) is
approximately 50.8 mm (2.00").
CAUTION: The maximum allowable reverse travel speed is 2 Km/hr.

b g
a

c d e
f wc_gr001358

wc_tx000295gb.fm 40
RD 7 /... Maintenance
5.13 Pressure Washing the Machine

When pressure washing the machine, avoid using harsh chemicals


and only use moderate water pressure (35–70 MPa [500–1000 psi]) .
Avoid direct pressure to the following components:
• Engine
• Hydraulic
• Water tank / Plastic parts
• Hoses
• Labels

5.14 Storing the Machine

If machine is to be stored for more than 30 days:


• Drain the fuel tank and the water tank.
• Open the water valve and drain water from the sprinkling system.
• Change the oil.
• Clean the entire roller and engine compartment.
• Remove dirt from the engine cooling fins.
• Cover the roller and place it in a dry, protected area.
• Remove the diesel injectors and put a little oil into the engine
cylinders.
• Remove battery from machine and charge it periodically (RD 7H-
ES).

wc_tx000295gb.fm 41
Maintenance RD 7 /...
5.15 Hoisting

See Graphic: wc_gr001359

Attach a sling or chain to the lifting eye (a) using a suitable hook or
shackle. Each lifting device must have capacity of at least 1430 lbs
(650 Kg).

Only use steel ropes or chains for hoisting. The rope or chain must
WARNING have the suitable specified lifting capacity of 1430 lbs (650 Kg). Do not
use improvised ropes or chains.

CAUTION: Never use any other part of the roller to lift the machine,
as severe damage may occur.

Do not stand under, or get onto, the machine while it is being hoisted
WARNING or moved.

wc_gr001359

wc_tx000295gb.fm 42
RD 7 /... Maintenance
5.16 Transporting

See Graphic: wc_gr001360


Before transporting the machine, place blocks in front of and behind
each drum. Use the front and rear tie-downs (b) to secure the machine
to the trailer. Lift handle (a) into upright position.
CAUTION: Never use any other part of the roller to tie the machine
down, as severe damage may occur.

wc_gr001360

wc_tx000295gb.fm 43
Maintenance RD 7 /...
5.17 Hydraulic Schematic
See Graphic: wc_gr001361, wc_gr0001362

Ref. Description Ref. Description


1. Exciter Relief Valve 9. Charge Pump
2. Exciter Control Valve 10. Exciter Pump
3. Exciter Motor 11. Drive Pump
4. Rear Drive Motor 12. Charge Pressure Relief Valve
5. Front Drive Motor 13. Internal Drive Pump Relief Valves
6. Return Filter 14. Porting Block
7. Suction Filter 15. Manifold
8. Pump Assembly

P 1
3
1
21 mPa
3000 PSI 2
2

12 13
10 mPa 20 mPa
1450 PSI 2900 PSI

5 4
11

10

10 micron
7

6 wc_gr001361

wc_tx000295gb.fm 44
RD 7 /... Maintenance
5.18 Hydraulic Diagram

15

2
8

14

wc_gr001362

wc_tx000295gb.fm 45
Maintenance RD 7 /...
5.19 Electrical Schematic (RD 7H-ES)

See Graphic: wc_gr001531

Ref. Description Ref. Description


1. Key Switch 5. Starter
2. 15 Amp fuse 6. Regulator
3. Alternator 7. Alarm
4. Battery

Wire Colors
B Black R Red Y Yellow Or Orange
G Green T Tan Br Brown Pr Purple
L Blue V Violet Cl Clear Sh Shield
P Pink W White Gr Gray LL Light Blue

wc_tx000295gb.fm 46
RD 7 /... Maintenance

wc_tx000295gb.fm 47
Maintenance RD 7 /...
5.20 Troubleshooting

Problem / Symptom Reason / Remedy


Engine does not start • Fuel tank empty.
• Wrong type of fuel.
• Old fuel. Drain tank, change fuel filter and fill with
fresh fuel.
• Fuel system not primed.
• Fuel filter restricted or plugged. Replace filter.
• Check / adjust valve clearance.
• Air cleaner element plugged.
• Check / adjust decompression device.
• Battery connections loose or corroded. Battery
dead (RD 7H-ES).
• Starter motor defective (RD 7H-ES).
• Electrical connections loose or broken (RD 7H-ES).
• Key switch defective (RD 7H-ES).
Engine stops by itself • Fuel tank empty.
• Fuel filter plugged.
• Fuel lines broken or loose.
No vibration • Valve damaged.
• Exciter assembly damaged.
• Exciter motor coupling damaged or broken.
• Exciter motor damaged.
• Pump damaged.
No travel • Control cable loose or broken.
or • Drive motor damaged.
Travel only in one direction
• Drive pump damaged.
• Defective relief valve or valves.

wc_tx000295gb.fm 48
RD 7 /... Repair General
6. General

6.1 Tools
Since all possible problems encountered while repairing the
equipment cannot be anticipated, it is up to the mechanic to use
common sense and good judgment in tool selection.
The use of any special tools is recommended only for those operations
where the use of conventional tools proves inadequate.
Before substituting another tool or procedure, you should be satisfied
that neither personal injury nor damage to the component will result.

6.2 Reference Numbers ( )


Repair procedures contain reference numbers enclosed in
parentheses ( ). These numbers refer to the item numbers shown on
the assembly drawings and other detailed drawings. They are included
to aid the mechanic in identifying parts and assembling components.

6.3 Ordering Parts


The repair procedures contained in this manual do not include part
numbers. For parts replacement information, refer to the Parts Manual
originally supplied with the unit.
If the original Parts Manual has been lost, a replacement manual may
be ordered from Wacker Corporation. When ordering a replacement
Parts Manual, please list model number, item number, and serial
number of machine.

6.4 Repair Accessories


In order to avoid contamination of the hydraulic system while repair
work involving hydraulic hoses is performed, the following plastic caps
and plugs for fitting ends are available:
Part Description Part Description
Number (Male) Number (Female)
0111709 Plug-fitting, #4 0111714 Cap-fitting, #4
0111710 Plug-fitting, #6 0111715 Cap-fitting, #6
0111711 Plug-fitting, #8 0111716 Cap-fitting, #8
0111712 Plug-fitting, #12 0111717 Cap-fitting, #12
0111713 Plug-fitting, #4, flare end 0111718 Cap-fitting, #4, flare end

wc_tx000350gb.fm 49
Hydraulic System RD 7 /... Repair
7. Hydraulic System

7.1 General Description

The hydraulic system is powered by two pumps mounted in tandem


and driven directly by the engine crankshaft through a flex coupling.
A single relief valve (1) is located on the manifold block.
The hydraulic system is protected by a return line filter which
removes particles down to 10 microns and includes a by-pass for cold
weather start-up.
A back pressure valve, located after the filter, maintains 14.5 psi (0.1
mPa) to the inlet side of the charge pump and ensures positive flow to
the drive pump to prevent cavitation.
The hydraulic tank is equipped with a strainer at the fill port to trap
large objects or particles which may accidentally fall into the tank while
adding hydraulic fluid. Additional system protection is provided by a
suction filter mounted inline with the exciter pump inlet.

7.2 Vibration

See Graphic: wc_gr001503


The vibration system is an open loop series circuit, driven by a fixed
displacement gear type pump. It includes separate relief valves for
vibration, an exciter control valve, and exciter motor.
The vibration circuit is controlled by the exciter control valve. This valve
is operated by an ON/OFF lever located on the handle. Supply oil from
the pump enters the manifold where it is directed to the exciter control
valve. When the lever is in the “OFF” position the exciter control valve
is open, allowing oil to pass through the system without driving the
exciter motor. When switched to “ON” the exciter control valve closes
and directs oil from the pump, out of the manifold, to the exciter motor
which drives the eccentric weight between the drums. A relief valve (1),
connected to the manifold, limits system pressure to 2000 psi (13.8
mPa).

wc_tx000351gb.fm 50
RD 7 /... Repair Hydraulic System
7.3 Hydraulic Manifold Block

1 2

7
5

6
wc_gr001503

Ref. Description Ref. Description


1 Relief Valve (3000 psi - 206 bar) 5 Exciter Motor Return Line
2 Exciter Control Pressure Lines 6 Porting Block Return Line
3 Exciter Pump Pressure Line 7 Filter Bypass Return Line
4 Exciter Motor Pressure Line

wc_tx000351gb.fm 51
Hydraulic System RD 7 /... Repair
7.4 Drive Circuit

The drive system is a closed loop circuit, consisting of a drive pump,


relief valve, and front and rear drive motors arranged in series. They
will drive at the same speed.
The drive pump is a variable displacement, piston type pump with an
integral charge pump. Charge pressure is maintained between 150–
210 psi (1.0–1.5 mPa) through an internal relief valve. Excess charge
pump flow is returned directly to tank.
The drive pump is manually actuated by the control lever mounted to
the end of the handle. When the control lever is shifted forward, oil is
directed from the high pressure side of the pump to the manifold block,
and downstream to both the front and rear drive motors. Return flow
from the motors is directed back through the manifold and returns to
the low pressure side of the drive pump.
When operating in reverse the high and low pressure sides of the drive
pump are reversed.
System pressure is limited to 2900 psi (20 mPa) by two relief valves in
the drive pump.

7.5 Return Line Filter

The oil returning from the vibration function is directed out of the
manifold to a return line filter. A back pressure valve located after the
filter is used to maintain 14.5 psi (0.1 mPa) to the inlet side of the
charge pump to supply the drive circuit. When pressure to the inlet of
the charge pump exceeds 14.5 psi the valve opens and returns the
excess flow back to the tank.

wc_tx000351gb.fm 52
RD 7 /... Repair Hydraulic System
7.6 Bleeding the Hydraulic System

See Graphic: wc_gr001504


7.6.1 Fill the hydraulic system with clean hydraulic oil until it is visible in the
sightglass. Do not re-use used hydraulic oil.
7.6.2 Disconnect the line (1) from drive pump. Fill pump case with hydraulic
oil through the open connection. Reconnect the line.
7.6.3 Start engine and run machine at full throttle. Move control slowly back
and forth from forward to reverse for a short time to bleed air trapped
in drive circuit.
7.6.4 Check hydraulic oil level and add oil as required.
Note: If drive pump chatters or operation is noisy, turn machine off and
check for air leaks in the inlet line of the charge pump.

wc_gr001504

wc_tx000351gb.fm 53
Hydraulic System RD 7 /... Repair
7.7 Hydraulic Diagram

P 1
3
1
21 mPa
3000 PSI 2
2

12 13
10 mPa 20 mPa
1450 PSI 2900 PSI

5 4
11

10

10 micron
7

6 wc_gr001361

Ref. Description Ref. Description


1. Exciter Relief Valve 9. Charge Pump
2. Exciter Control Valve 10. Exciter Pump
3. Exciter Motor 11. Drive Pump
4. Rear Drive Motor 12. Charge Pressure Relief Valve
5. Front Drive Motor 13. Internal Drive Pump Relief Valves
6. Return Filter 14. Porting Block
7. Suction Filter 15. Manifold
8. Pump Assembly

wc_tx000351gb.fm 54
RD 7 /... Repair Hydraulic System
7.8 Hydraulic Schematic

15

2
8

14

wc_gr001362

wc_tx000351gb.fm 55
Hydraulic System RD 7 /... Repair
7.9 Test Hydraulic Pressures

Before making pressure checks:

7.9.1 Inspect machine for hydraulic leaks.

7.9.2 Check level of hydraulic fluid in tank.

7.9.3 Check engine operating speed at full throttle.

7.9.4 Run machine for 5-10 minutes before testing to allow time for hydraulic
system to warm up.

Note: There are no designated test ports on the hydraulic block. Use
pressure fittings and adapters designed for use with Wacker hydraulic
test equipment.
Before opening hydraulic connections, shut engine off and make sure
all controls are in neutral.
WARNING

7.10 Check Vibration Circuit

See Graphic: wc_gr001505


Test vibration with roller on soil or gravel. If testing is done inside,
position roller on heavy mat to absorb vibration.
CAUTION: Do not run vibration on concrete.

7.10.1 Remove vibration pressure line (1) from hydraulic manifold (2).

7.10.2 Install a #6 T-fitting and test fitting into manifold. Install 5000 psi gauge
in test fitting.

7.10.3 Start engine and run machine at full throttle, forward/reverse control in
neutral.

7.10.4 Switch vibration on. Gauge will read relief pressure momentarily as
exciter starts and then fall to normal operating pressure as exciter
reaches full speed.

If it is not possible to read the relief valve pressure accurately,


disconnect the exciter motor inlet line (3) on the manifold. Cap off and
plug open line connections. Start engine and run test. If pump is in
good condition gauge will immediately come up to relief valve pressure
and remain there.

wc_tx000351gb.fm 56
RD 7 /... Repair Hydraulic System

a 1
d
f

b
e
c

2
3

wc_gr001505

Ref. Description Part No. Part No.

10 mPa (1000 psi) 30 mPa (5000 psi)


a. Pressure Gauges
0077999 0078000

b. Gauge Adapter 0078005 -

c. Hose 0078002 -

d. Test Fitting 0089203 -

Hex Nut #6 0087227 #8 0116798


e.
ORFS Adapter #6 0087228 #8 0116799

f. T-Fitting #6 0083412 #8 0078000

wc_tx000351gb.fm 57
Hydraulic System RD 7 /... Repair
7.11 Checking Drive Circuit

See Graphic: wc_gr001506

Operating Pressure

Check operating pressures with the machine on a firm, level surface.

7.11.1 Remove drive pressure line (3) from hydraulic pump (1).

7.11.2 Install a #6 T-fitting (2) and test fitting (4) into pump. Install 5000 PSI
gauge in test fitting.

7.11.3 Start engine and run at full throttle.

7.11.4 Shift control lever into either forward or reverse and read operating
pressure.

Note: Operating pressures will increase significantly when running


machine uphill, off road or against an object.

Relief Pressure

7.11.5 Block in front of and behind both drums to prevent machine from
moving or dead head machine against a solid concrete abutment.

Make sure blocks are large enough so machine will not climb over
them during testing.
WARNING

7.11.6 Install a 5000 PSI gauge in test fitting (4).

7.11.7 Start engine and run machine at full throttle. Shift control slowly into
forward or reverse until pressure on gauge tops out. This is the forward
or reverse relief valve pressure.

Note: Make sure drums do not spin.

wc_tx000351gb.fm 58
RD 7 /... Repair Hydraulic System

1
2

3
4
wc_gr001506

Normal Operating Relief Valve


Pressure bar (psi) Pressure bar (psi)

Forward 69 (1000) 200 (2900)


Reverse 41 (600) 200 (2900)
Exciter 69 (1000) 138 (2000)

wc_tx000351gb.fm 59
Hydraulic System RD 7 /... Repair
7.12 Relief Valves

See Graphic: wc_gr001507


Relief valves are preset at the factory and normally do not require
further adjustment. Any valve adjustment is done by shims. However,
adjusting relief valves is not recommended, as shims are not spare
parts. Replace complete relief valve.
CAUTION: Do not increase pressures above machine specifications!
Higher pressures can damage pumps and motors.
Drive Circuit Reliefs
Current machines have relief valves built into the drive pump (1).
These reliefs are preset at 2900 psi (200 bar) and do not require further
adjustment unless operating at below the recommended setting.
Exciter Relief Pressure
DO NOT remove plug or attempt to set valve while engine is running
or system is under pressure!
WARNING

7.12.1 Turn engine off.


7.12.2 Remove plug (2) from end of valve (3) to expose adjusting screw.
7.12.3 Use a 1/4" Allen wrench (4) and turn adjusting screw in or out until
correct pressure is set.
7.12.4 Install plug back in valve prior to starting engine.

4
2
3
1
wc_gr001507

wc_tx000351gb.fm 60
RD 7 /... Repair Hydraulic System
7.13 Troubleshooting Vibration System

The exciter pump is designed to put out a constant flow of oil at a set
engine speed. This ensures that the vibration frequency remains
steady. When troubleshooting the exciter circuit, the vibration speed
should be measured along with the operating and relief pressures to
help determine the cause of any problems.
To measure vibration speed:
7.13.1 Start machine and run it for several minutes to bring hydraulic fluid up
to normal operating temperatures.
7.13.2 Check engine RPM using a tachometer. The engine must be running
at the correct RPM to accurately measure vibration.
7.13.3 Position roller on a rubber mat and start vibration. Hold vibrotach (P/N
53397) against outer rim on drum and measure vibration speed.

Minimum
Engine RPM
Vibration Speed

2700–2900 3300

7.13.4 The vibration speed along with the operating and relief valve pressures
can be used to determine the condition of the exciter system as shown
in chart below.
If the exciter is binding, causing high operating pressures, it will be
necessary to disconnect and remove the exciter motor from the
housing to determine if the binding is occurring in the exciter bearings
or the motor. Turn motor shaft and exciter shaft by hand and check that
they turn freely.

Operating Pump Relief


Exciter Speed Probable Cause
Pressure Pressure

N N N System OK

H N N or L Exciter bearings or motor binding

N or L N L Exciter motor worn

Exciter pump damaged or worn,


L L L relief valve defective, or needs
adjusting.

N = Normal, L = Low, H = High

wc_tx000351gb.fm 61
Hydraulic System RD 7 /... Repair
7.14 Troubleshooting Drive System

See Graphic: wc_gr001508


Stop the machine, apply the parking brake and switch off the machine.
High operating pressures indicate binding in the drive system. Binding
can occur in the drive motor or may be the result of a poor or failing
drive bearing located on the right side of the drum.
To check for binding in the drive motor:

7.14.1 Tag and disconnect hydraulic lines to drive motor. Cap or plug all open
connections. For recommended caps or plugs, see Repair
Accessories.

Before dismantling hydraulic connectors or hoses, ensure that all


pressure has been relieved from the circuit. Open hose fittings slowly.
WARNING
Note: In the interests of environmental protection, place a plastic sheet
and a container under the machine to collect the liquid which drains off
and dispose of properly.

7.14.2 Remove four screws (1) mounting porting block (2) to lower frame.
Tag, disconnect, and cap three upper hydraulic lines (3) from porting
block.

7.14.3 Support the machine before separating drum from frame by attaching
a sling or chain to the lifting eye (4) using a suitable hook or shackle.
Each lifting device must have capacity of at least 1430 lbs (650 Kg).

Only use slings or chains for hoisting. The sling or chain must have the
suitable specified lifting capacity. Do not use improvised slings or
WARNING chains.
CAUTION: Never use any other part of the roller to lift the machine, as
severe damage may occur.

7.14.4 Remove six screws (5) mounting drum support to frame. Remove
drum out from frame.

Do not stand under the machine while it is being hoisted or moved.

WARNING

Note: Failure of the drive circuit to reach operating pressures is


normally caused by a worn or damaged drive pump, although the
problem could also be the result of a badly worn motor. Questions
regarding testing and troubleshooting of drive component failures
should be referred to Wacker Corporation.

wc_tx000351gb.fm 62
RD 7 /... Repair Hydraulic System

3
2
1

5
wc_gr001508

wc_tx000351gb.fm 63
Power Take-Off RD 7 /... Repair
8. Power Take-Off

8.1 Description

See Graphic: wc_gr001509


The pumps used to power the hydraulic system are driven directly by
the engine through a flywheel coupling or clutch (1). The pumps are
connected along their shafts through a solid mounted coupling (2).
The exciter pump (3) is a fixed displacement gear type pump and
provides a constant flow of oil to operate the vibration circuit.
The drive pump (4) is a variable displacement axial piston pump. Flow
through this pump is controlled by varying its displacement through the
movement of a lever attached to its control shaft (5). This allows a full
range of operating speeds in both forward and reverse.
Note: Wacker Corporation does not recommend the disassembly or
attempted repair of hydraulic components (pumps, motors) by anyone
other than a trained hydraulic repair technician. Repair and rebuilding
of hydraulic components may be available from component
manufacturers. Hydraulic component parts are not available from
Wacker Corporation.

wc_tx000352gb.fm 64
RD 7 /... Repair Power Take-Off
8.2 Pump Assembly

4
2
3

5
1

wc_gr001509

wc_tx000352gb.fm 65
Power Take-Off RD 7 /... Repair
8.3 Drive Pump

See Graphic: wc_gr001510


Removal
CAUTION: The failure of a drive pump or motor caused by factors
other than normal wear can contaminate the drive circuit with metal
particles.
8.3.1 Thoroughly clean pump and hose connections.
Danger of burns! Pump may be hot—care must be taken when
removing hydraulic components and oil. Hot oil can burn!
WARNING

8.3.2 Tag and disconnect hose lines (1) from pump. Cap or plug all open
connections. For recommended caps or plugs, see Repair
Accessories.
Before dismantling hydraulic connectors or hoses, ensure that all
pressure has been relieved from the circuit. Open hose fittings slowly.
WARNING
8.3.3 Remove the support bracket (2) from the exciter pump (3). Save
locknuts (4) and washers (5) for remounting.
8.3.4 Remove two locknuts (6) holding exciter pump to drive pump (7).
8.3.5 Remove 2 mounting screws (8) holding drive pump to engine / pump
adapter.
8.3.6 Remove control lever (9), hydraulic fittings (10), O-ring (11) and
coupling (12) and transfer to new pump.
Installation
8.3.7 Install new pump and fasten it to engine / pump adapter. Secure
mounting screws (8) using Loctite 271 or an equivalent high strength
threadlocker.
8.3.8 Install exciter pump (3) to new drive pump using locknuts (6).
8.3.9 Install support bracket (2) to exciter pump using locknuts (4) and
washers (5).
8.3.10 Reconnect hose lines (1) to fittings (10).
8.3.11 Bleed drive circuit.
CAUTION: It is recommended that the drive circuit be flushed after a
pump failure to remove any contaminants which may be trapped in the
lines.
Before you start the machine, ensure that all tools have been removed
from the machine and that replacement parts and adjusters are firmly
WARNING tightened.

wc_tx000352gb.fm 66
RD 7 /... Repair Power Take-Off

10

8
1
7

12
9

10
5 11
4
3 1

2 wc_gr001510

wc_tx000352gb.fm 67
Power Take-Off RD 7 /... Repair
8.4 Exciter Pump

See Graphic: wc_gr001511

Removal

8.4.1 Thoroughly clean pump and hose connections.

Danger of burns! Pump may be hot—care must be taken when


removing hydraulic components and oil. Hot oil can burn!
WARNING

8.4.2 Tag and disconnect hose lines (1) from exciter pump (3). Cap or plug
all open connections. For recommended caps or plugs, see Repair
Accessories.

Before dismantling hydraulic connectors or hoses, ensure that all


pressure has been relieved from the circuit. Open hose fittings slowly.
WARNING

8.4.3 Remove the support bracket (2) from the exciter pump (3). Save
locknuts (4) and washers (5) for remounting.

8.4.4 Remove two locknuts (6) holding exciter pump to drive pump (7).

8.4.5 Remove O-ring (8), coupling (9) and fitting (10) and transfer to new
pump.

Installation

8.4.6 Install new exciter pump (3) to drive pump (7) using locknuts (6).

8.4.7 Install support bracket (2) to exciter pump using locknuts (4) and
washers (5).

8.4.8 Reconnect hose lines (1) to fitting (10).

8.4.9 Bleed hydraulic system before starting. See Bleeding the Hydraulic
System.

Before you start the machine, ensure that all tools have been removed
from the machine and that replacement parts and adjusters are firmly
WARNING
tightened.

wc_tx000352gb.fm 68
RD 7 /... Repair Power Take-Off

1
7

5 8 1
4
3
6
10
2 wc_gr001511

wc_tx000352gb.fm 69
Power Take-Off RD 7 /... Repair
8.5 Engine

See Graphic: wc_gr001512


Removal
Stop the machine, apply the parking brake and switch off the machine.
8.5.1 Tag and disconnect all hoses and throttle cable that are attached to the
engine.
8.5.2 Tag and disconnect all hose lines from exciter and drive pumps.
Disconnect control lever bracket (1) mounted to drive pump. Cap all
open connections. For recommended caps or plugs, see Repair
Accessories.
Before dismantling hydraulic connectors or hoses, ensure that all
pressure has been relieved from the circuit. Open hose fittings slowly.
WARNING

8.5.3 Remove the pump support bracket (2) at the front of the hydraulic
pump (3).
8.5.4 Remove exhaust pipe (4).
8.5.5 Attach lifting ropes or chains to engine’s lifting eye.
Note: The engine lifting eye (104439) was originally packaged with the
HATZ engine manual. To install lifting eye, remove throttle bracket (5)
and mount lifting eye in its place.
Only use slings or chains for hoisting. Slings or chains must have the
suitable lifting capacity. Do not use improvised slings or chains.
WARNING

8.5.6 Remove screws (6), washers (7), and nuts (8) that mount the engine
to the frame.
8.5.7 Leaving the pump mounted to the engine, lift the engine slightly to
check that it is correctly balanced.
8.5.8 Lift and remove engine from machine.
Do not stand under or get near the engine, while it is being hoisted or
moved.
WARNING

8.5.9 Remove hydraulic pump (3) and Pump adapter (9). On older versions
(10a), loosen screw (15) and remove coupler (14) from shaft. A pry bar
between coupler and shaft may be needed. Remove six screws (11)
mounting flywheel coupling to engine.
8.5.10 On newer versions (10b), the pump mounts directly into the clutch.
Remove two screws (16) and washers (17) mounting clutch to engine.

wc_tx000352gb.fm 70
RD 7 /... Repair Power Take-Off

10b

11 16
4 14
6 15 17
9 1
7
13

10a
3
12
2

8
wc_gr001512

wc_tx000352gb.fm 71
Power Take-Off RD 7 /... Repair
Installation

8.5.1 Apply a medium strength threadlocker to six screws (11) mounting


flywheel coupling (10) to engine. Torque screws to 18 ft.lbs. (25 Nm).

8.5.2 Apply a medium strength threadlocker to screw (15) mounting coupler


(14) to pump shaft. Torque screw to 45 ft.lbs. (60 Nm).

8.5.3 Apply a medium strength threadlocker to ten screws (12) mounting


pump adapter (9) to engine. Torque screws to 51 ft.lbs. (69 Nm).

8.5.4 Apply a medium strength threadlocker to two screws (13) mounting


hydraulic pump (3) to engine. Torque screws to 36 ft.lbs. (49 Nm).

8.5.5 Attach lifting ropes or chains to engine’s lifting eye.

Only use steel ropes or chains for hoisting. Ropes or chains must have
the suitable lifting capacity. Do not use improvised ropes or chains.
WARNING
8.5.6 Lift engine and place in machine.

8.5.7 Install pump support bracket (2) onto hydraulic pump.

8.5.8 Mount engine to frame reusing screws (6), washers (7) and nuts (8).

8.5.9 Attach pump support bracket to frame.

8.5.10 Attach exhaust pipe (4) to engine.

8.5.11 Attach all hose lines to pumps.

8.5.12 Attach all electrical wiring and throttle cable to engine.

8.5.13 Attach control lever bracket (1) to drive pump. The drive control cable
may need to be adjusted. See Direction Lever Adjustment.

8.5.14 The engine valve clearance may need to be adjusted. See Checking
and adjusting valve clearances.

Note: See sealant and torque reference charts in back of book for
appropriate threadlocking adhesives and torque values.

Before you start the machine, ensure that all tools have been removed
from the machine and that replacement parts and adjusters are firmly
WARNING tightened.

wc_tx000352gb.fm 72
RD 7 /... Repair Roller
9. Roller

9.1 Drum - Description

See Graphic: wc_gr001513

The front and rear drums operate as static rollers to aid in smoothing
and finishing.

The front and rear drums are driven by hydraulic motors (1) each motor
is mounted to a drive hub (17), which is mounted directly to the left side
of each drum. The drive motor is designed to provide low speeds and
high torques without the need for any type of speed reduction gears,
belts or pulleys.

A mechanical parking brake (16) is attached to the rear drum on the


right side and is used to ensure that the machine will not roll when not
in use. The brake is mounted directly to the drum support and is
engaged and disengaged by the operator.

CAUTION: The parking brake is designed to hold the machine on an


incline with the engine off. Do not drive against the parking brake in the
engaged position. The brake may bend and damage the machine.

Note: Wacker Corporation does not recommend the disassembly or


attempted repair of hydraulic components (pumps, motors) by anyone
other than a trained hydraulic repair technician. Repair and rebuilding
of hydraulic components may be available from component
manufacturers. Hydraulic component parts are not available from
Wacker Corporation.

wc_tx000353gb.fm 73
Roller RD 7 /... Repair
9.2 Drum

See Graphic: wc_gr001514


Removal
Stop the machine, apply the parking brake, and switch off the engine.
CAUTION: Before removing the drum, clean and wash the complete
drum assembly to remove as much dirt as possible. Be especially
thorough when cleaning area around tube and hose connections on
motors. This will minimize the chance of contamination when opening
hydraulic lines.
9.2.1 Tag and disconnect hydraulic lines to drive motor. Cap or plug all open
connections. For recommended caps or plugs, see Repair
Accessories.
Before dismantling hydraulic connectors or hoses, ensure that all
pressure has been relieved from the circuit. Open hose fittings slowly.
WARNING

9.2.2 Remove four screws (1) mounting porting block (2) to lower frame.
Tag, disconnect, and cap three upper hydraulic lines (3) from porting
block.
9.2.3 Support the machine before separating drum from frame by attaching
a sling or chain to the lifting eye (4) using a suitable hook or shackle.
Each lifting device must have capacity of at least 1600 lbs. (725 Kg.).
Only use slings or chains for hoisting. The sling or chain must have the
suitable specified lifting capacity. Do not use improvised slings or
WARNING chains.
CAUTION: Never use any other part of the roller to lift the machine, as
severe damage may occur.
Do not stand under the machine while it is being hoisted or moved.

WARNING

9.2.4 Remove six screws (5) mounting drum support to frame. Remove
drum out from frame.

wc_tx000353gb.fm 74
RD 7 /... Repair Roller

wc_gr001514

Installation
9.2.1 Position drum under machine frame and line up holes in drum support
(6) with holes in frame.
9.2.2 Mount drum to frame using six screws (5). Apply Loctite 243 or an
equivalent medium strength threadlocker and torque to 88 ft.lbs. (120
Nm).
9.2.3 Reconnect all hydraulic hoses to drive motors.
9.2.4 Reconnect all hydraulic hoses (3) to porting block (2). Mount porting
block to lower frame using four screws (1). Apply Loctite 243 or an
equivalent medium strength threadlocker and torque to 36 ft.lbs. (49
Nm).
Note: See sealant and torque reference charts in back of book for
appropriate threadlocking adhesives and torque values.
Before you start the machine, ensure that all tools have been removed
from the machine and that replacement parts and adjusters are firmly
WARNING tightened.

wc_tx000353gb.fm 75
Roller RD 7 /... Repair
9.3 Drum Assembly

See Graphic: wc_gr001513


Disassembly
9.3.1 Remove drum from machine. See Drum Removal / Installation.
9.3.2 Stand drum on end with driver motor (1) facing up.
9.3.3 Remove the four screws (2) that hold the drive motor and drum support
(3) to the drive hub (4a).
CAUTION: When removing drive motor, care must be taken to ensure
splined shaft does not separate from inside of motor. Also, note angle
at which drive motor is mounted.
9.3.4 Remove retaining ring (5) holding the drive hub to shaft on drive hub
(6).
9.3.5 Remove retaining ring (7) holding the roller bearing (8) in drive hub
(4a).
9.3.6 Press roller bearing from hub.
To remove drive hub (6) from drum:
9.3.7 Remove four screws (9).
9.3.8 Remove two screws (10) and washers (11) to expose puller holes.
9.3.9 Use two M12 pusher screws and turn until drive hub (6) is pulled free
of drum.
Assembly
9.3.10 Mount drive hub (6) to drum using four screws (9). Apply Loctite 243 or
an equivalent medium strength threadlocker and torque to 88 ft.lbs.
(120 Nm).
9.3.11 Before pressing bearing (8) into drive hub (4a), inspect shaft seal (12)
for cracking and proper alignment in drive hub.
9.3.12 Press bearing into drive hub and secure with retaining ring (7).
Note: On non-drive side only, pack bearing and hub (4b) with wheel
bearing grease Filmite EMB or equivalent.
Note: On non-drive side only, shims (15) are factory installed. If
removal is necessary, replace with the same quantity that was
provided with each drum.
9.3.13 Place drive hub (4a) over shaft of drive hub (6) ensuring lip of seal (13)
lays flat on surface. Secure with retaining ring (5).
9.3.14 Align drum support (3), O-ring (14) and drive motor (1) with drive hub
(4a) and secure with four screws (2). Apply Loctite 243 or an
equivalent medium strength threadlocker and torque to 63 ft.lbs. (86
Nm).

wc_tx000353gb.fm 76
RD 7 /... Repair Roller
CAUTION: When installing drive motor, care must be taken to ensure
splined shaft does not separate from inside of motor. Also, mount drive
motor at the correct angle.
Note: See sealant and torque reference charts in back of book for
appropriate threadlocking adhesives and torque values.
Before you start the machine, ensure that all tools have been removed
from the machine and that replacement parts and adjusters are firmly
WARNING tightened.

16

4b

15

13
6 17
12
11

10
14
4a
8
7
5
3 1
2
wc_gr001513

wc_tx000353gb.fm 77
Roller RD 7 /... Repair
9.4 Exciter

See Graphic: wc_gr001515


Removal
CAUTION: Before removing the exciter, clean and wash the complete
exciter assembly to remove as much dirt as possible. Be especially
thorough when cleaning area around tube and hose connections on
motors. This will minimize the chance of contamination when opening
hydraulic lines.
9.4.1 Remove top cover (1) by removing six screws (2).
9.4.2 Drain water tank by disconnecting hose (3) from fitting (4).
9.4.3 Remove water tank (5) by removing two screws (6) attaching tank to
frame and remove the screw (7) and washer (8) from the bracket
located under the water tank.
9.4.4 Drain hydraulic fluid. See Changing Hydraulic Fluid and Filter - steps
1-4.
9.4.5 Tag and disconnect the three hydraulic hoses (9) from the exciter
motor (10) and three hoses (11) from the porting block (12).
Before dismantling hydraulic connectors or hoses, ensure that all
pressure has been relieved from the circuit. Open hose fittings slowly.
WARNING Note: In the interests of environmental protection, place a plastic sheet
and a container under the machine to collect the liquid which drains off,
and dispose of properly.
9.4.6 Remove both front and rear plates (13) from upper frame (14) by
removing two screws (15) on each plate.
9.4.7 Remove the shockmount screws (16) and washers (17) that secure the
shockmounts (18) to the lower frame (19).
9.4.8 Support the machine by attaching a sling or chain to the lifting eye (20)
using a suitable hook or shackle. Each lifting device must have
capacity of at least 1000 lbs. (454 Kg.).
Only use slings or chains for hoisting. The sling or chain must have the
suitable specified lifting capacity. Do not use improvised slings or
WARNING chains.
Do not stand under the machine while it is being hoisted or moved.
CAUTION: Never use any other part of the roller to lift the machine, as
severe damage may occur.
9.4.9 Remove upper mass of machine by using central lifting eye (20).
9.4.10 Remove inner scraper bar (21) by removing two center screws (22)
and washers (23).
9.4.11 Remove four screws (24) and washers (25) mounting exciter assembly
(26) to lower frame (19).

wc_tx000353gb.fm 78
RD 7 /... Repair Roller

5
4
3
C B
20
8 A D
7 a
6
15
13
15
13

14

1
2
26
27

18
17
16

19

25
24
10
21 11

12
23 9
22
wc_gr001515

wc_tx000353gb.fm 79
Roller RD 7 /... Repair
Installation
9.4.1 Place exciter assembly (25) on frame. Rock housing on frame to
determine which corner needs to be shimmed. Shim (27) as needed
between the frame and the housing.
9.4.2 Mount exciter assembly to frame using four screws (24) and washers
(25). Apply Loctite 243 or an equivalent medium strength threadlocker.
Torque screws in sequence A, B, C, D. (a) following these steps:
• Step 1 - snug by hand
• Step 2 - 40 ft. lbs. ( 54 Nm)
• Step 3 - 88 ft. lbs. (120 Nm)
• Step 4 - 88 ft. lbs. (120 Nm)
9.4.3 Replace scraper bar (21) with two screws (22) and washers (23).
9.4.4 Replace upper mass of machine over lower mass by using the central
lifting eye (20).
9.4.5 Reinstall the screws (16) and washers (17) for shock mounts (18)
using Loctite 243 or an equivalent medium strength threadlocker and
torque to 63 ft. lbs. (86 Nm).
9.4.6 Remount both front and rear plates (13) and screws (15) to upper
frame (14).
9.4.7 Reconnect the three hydraulic hoses (9) to exciter motor (10) and three
hoses (11) to porting block (12).
9.4.8 Fill hydraulic tank with hydraulic oil (SAE 10W 30) until the level is
visible halfway up the sight glass. Run engine briefly, then stop the
engine and check for leaks. Check the level in the sight glass, and top
off if necessary.
9.4.9 Remount water tank (5) with three screws (6 & 7) and washer (8).
9.4.10 Remount top cover (1) with six screws (2).
9.4.11 Reconnect water hose (3) to fitting (4).
Note: See sealant and torque reference charts in back of book for
appropriate threadlocking adhesives and torque values.
Before you start the machine, ensure that all tools have been removed
from the machine and that replacement parts and adjusters are firmly
WARNING tightened.

wc_tx000353gb.fm 80
RD 7 /... Repair Roller
9.5 Exciter Assembly

See Graphic: wc_gr001516

Disassembly

9.5.1 Remove the exciter assembly from the frame. See Exciter.

9.5.2 Remove four screws (1) mounting exciter motor (2) to cover plate (3).

9.5.3 Remove ten screws (4) mounting cover plates (3) and (8) to exciter
housing (5).

9.5.4 Press bearings (6a) and (6b) shaft (7) as a unit from housing. Inspect
bearings for damage and replace if necessary.

Assembly

9.5.5 Press non-motor side bearing (6b) into exciter housing (5) .

9.5.6 Turn housing on end with motor side facing up, insert shaft (7) with
splined end facing up and press into lower bearing.

9.5.7 Press motor side bearing (6a) into housing and over shaft.

9.5.8 Mount cover plates (3) and (8) to housing using ten screws (4). Apply
Loctite 243 or an equivalent medium strength threadlocker and torque
to 7 ft.lbs. (10 Nm).

Note: Orientation of cover plate (3) must be as shown to mount exciter


motor properly.

9.5.9 Mount exciter motor (2) to cover plate (3) using four screws (1). Apply
Loctite 243 or an equivalent medium strength threadlocker and torque
to 7 ft.lbs. (10 Nm).

Note: See sealant and torque reference charts in back of book for
appropriate threadlocking adhesives and torque values.

Before you start the machine, ensure that all tools have been removed
from the machine and that replacement parts and adjusters are firmly
WARNING tightened.

wc_tx000353gb.fm 81
Roller RD 7 /... Repair

6b

8 6a

5
4
1

7 2

wc_gr001516

wc_tx000353gb.fm 82
RD 7 /... Repair Roller
9.6 Throttle Cable

See Graphic: wc_gr001517


Removal
9.6.1 Remove setscrew (1) holding throttle cable (2) to cam on engine.
9.6.2 Loosen nut (3) and remove cable support (4).
9.6.3 Pull sleeve (5) from cable support and remove cable.
9.6.4 Loosen nut (6) that mounts throttle control (7) to bracket (8).
Installation
9.6.5 Feed throttle cable (2) through bracket (8), sleeve (5) and cable
support (4).
9.6.6 Press sleeve into cable support and mount cable support to bracket
(9). Tighten nut (3).
9.6.7 Feed cable through throttle pin (10). Before securing cable with
setscrew (1), adjust so machine runs at specified RPM at full throttle
control. See Technical Data.
9.6.8 Mount throttle control (7) to bracket (8). Tighten nut (6).
Before you start the machine, ensure that all tools have been removed
from the machine and that replacement parts and adjusters are firmly
WARNING tightened.

8 5
6 4
3
7

10
1
2

wc_gr001517

wc_tx000353gb.fm 83
Roller RD 7 /... Repair
9.7 Direction Cable

See Graphic: wc_gr001518

Removal

9.7.1 Remove pin (1) from pivot bracket (2). Unscrew from cable (3).

9.7.2 Loosen nut (4) on spring cylinder (5).

9.7.3 Unscrew Hydroback from cable.

9.7.4 Loosen nut (6) that mounts cable to bracket (7).

9.7.5 Remove four screws (8) mounting covers (9) to expose handle linkage.

9.7.6 Remove cable ball end (10) from pivot plate. Unscrew from cable.

9.7.7 Loosen nut on cable mounted to handle and remove.

Installation

9.7.8 Feed cable (3) through handle frame. Screw cable end into cable ball
end (10).

9.7.9 Mount cable ball end to pivot plate.

9.7.10 Feed cable into spring cylinder (5). Screw on until cable bottoms out.

9.7.11 Screw pin (1) into cable end.

9.7.12 Mount cable to bracket (7). Tighten nut (6).

9.7.13 Tighten nut (4) on Hydroback.

9.7.14 Attach pin (1) to pivot bracket (2).

9.7.15 Before mounting covers, the cable needs to be adjusted properly. See
Direction Lever Adjustment.

Before you start the machine, ensure that all tools have been removed
WARNING
from the machine and that replacement parts and adjusters are firmly
tightened.

wc_tx000353gb.fm 84
RD 7 /... Repair Roller

2
1

5
4
10
3
6

9
8 wc_gr001518

wc_tx000353gb.fm 85
Roller RD 7 /... Repair
9.8 Direction Control Lever

See Graphic: wc_gr001519


Removal
9.8.1 Remove four screws (1) holding covers (2) to handle frame (3).
9.8.2 Disconnect cable ball end (4) from pivot plate (5).
9.8.3 Remove screw (6) holding lever assembly to frame.
9.8.4 Remove shaft (7) and spring (8).
9.8.5 Remove pivot hub (9) from pivot plate (5) by disconnecting retaining
ring (10). Press bearing (11) from pivot hub.
9.8.6 Press pin (12) from direction handle (13).
9.8.7 Press bearing (14) from direction handle.
To remove plunger shaft:
9.8.8 Unscrew plunger (16) from shaft end (17).
9.8.9 Slide spring (18) off of shaft and pull shaft through guide handle (19).
9.8.10 Press two bearings (20) from guide handle.
Installation
9.8.11 Press bearing (14) into direction handle (13).
Note: Make sure bearing is flush with backside of direction handle.
9.8.12 Apply Loctite 271 or an equivalent high strength threadlocker on pin
(12) and press into directional handle .90 ±.01 in. (22 ±.25 mm).
9.8.13 Press bearing (11) into pivot hub (9).
Note: Make sure bearing is flush with front side of pivot hub.
9.8.14 Insert pivot hub into pivot plate (5) and secure with retaining ring (10).
9.8.15 Slide spring over shaft.
9.8.16 Insert shaft (7) through spring (8), pivot hub (9) and direction handle
(13), and mount to handle frame (3) using screw (6) and nut (15).
9.8.17 Reattach cable ball end (4) to pivot plate (5).
9.8.18 Mount covers (2) to handle frame using four screws (1). Apply Loctite
243 or an equivalent medium strength threadlocker and torque to 18
ft.lbs. (25 Nm).
To install plunger shaft:
9.8.19 Press two bearings (20) into guide handle (19).
Note: Make sure bearings are flush with both sides of guide handle.
9.8.20 Insert shaft (17) through guide handle. Slide spring (18) over shaft.
9.8.21 Screw plunger (16) onto end of shaft. Apply Loctite 243 or an
equivalent medium strength threadlocker.

wc_tx000353gb.fm 86
RD 7 /... Repair Roller
Note: See sealant and torque reference charts in back of book for
appropriate threadlocking adhesives and torque values.
Before you start the machine, ensure that all tools have been removed
from the machine and that replacement parts and adjusters are firmly
WARNING tightened.

14

12
5
2 15 4
3 13
19
10
11
9
8
7
6

18 16

2
17 20

1
wc_gr001519

wc_tx000353gb.fm 87
Troubleshooting RD 7 /... Repair
10. Troubleshooting

10.1 General

The troubleshooting charts which follow provide basic guidelines to


help you diagnose and remedy equipment problems. Keep in mind that
every possible problem cannot be anticipated. Should questions arise
during the service or repair of this equipment please contact Wacker
Corporation for assistance.
Before removing any parts or making adjustments, conduct a visual
inspection of the machine and check for:
10.1.1 Dirty air and fuel filters.
10.1.2 Rocks or dirt obstructing the movement of drums, and scraper bar
assemblies.
10.1.3 Leaks in hydraulic lines and fittings.
10.1.4 Low oil levels in engine crankcase, exciter and hydraulic tank.
10.1.5 Loose mounting hardware on pumps or motors.
10.1.6 Broken linkage and cables.

10.2 Vibration System

Problem / Symptom Reason / Remedy


No Vibration. • Vibration switch not on or defective. Check and
replace.
• Exciter motor or bearings seized. Check exciter
motor & bearings.
Vibration slow. • Engine speed too low. Run engine at full speed.
Check engine and vibration RPM.
• Exciter motor or bearing binding. Remove exciter
motor. Rotate motor and shafts by hand. Check
hydraulic operating pressures.
• Exciter motor worn. Check vibration speed and
operating pressure.

wc_tx000354gb.fm 88
RD 7 /... Repair Troubleshooting
10.3 Drive System

Problem / Symptom Reason / Remedy


Machine does not climb • Drums spinning. Ground material loose or slippery.
grade. • Grade too steep. Measure angle of grade.
• Relief pressure low or relief valve defective. Check
relief pressure. Replace or adjust relief valve.
• Drive pump or drive motors damaged or worn.
Consult Wacker Corporation.
Machine does not travel or • Engine speed too low. Run engine at full throttle.
travels slowly or erratically. Check engine RPM.
• Hydraulic fluid cold or wrong type. Allow fluid to
warm up. Check fluid against specifications.
• Control cable ends disconnected or broken. Check
cable and connections. Repair or replace as
required.
• Control lever pin sheared. Check and repair.
• Drive bearings seized. Inspect drive bearings.
Check bearing lubrication.
• Drive pump worn or defective. Consult Wacker
Corporation. Replace pump.
• Drive motor worn. Consult Wacker Corporation.
Replace motor.
• Relief valve pressure low. Check and adjust relief
valve
• Air trapped in hydraulic oil. Check suction hose.
Tighten connections or replace.

wc_tx000354gb.fm 89
Troubleshooting RD 7 /... Repair
10.4 Starting System

Problem / Symptom Reason / Remedy


Engine turns over but won’t • Fuel tank is empty. Fill fuel tank.
start or starts hard. • Wrong type of fuel. Use correct fuel type.
• Old fuel. Drain tank, change fuel filter and fill with
fresh fuel.
• Fuel filter restricted or plugged. Replace fuel filter.
• Incorrect valve clearance. Check / adjust valve
clearance.
• Air cleaner element plugged. Check and replace air
filter.
• Vibration switch on, loading down hydraulic system.
Turn switch off.
• Hydraulic oil or engine oil too heavy. Check
specifications and fill with correct oil.
• Temperature is too cold. Warm engine. Change
engine oil to a higher grade.

wc_tx000354gb.fm 90
Threadlockers and Sealants
Threadlockers and Sealants
Threadlocking adhesives and sealants are specified throughout this
manual by a notation of “S” plus a number (S#) and should be used
where indicated. Threadlocking compounds normally break down at
temperatures above 175°C (350°F). If a screw or bolt is hard to
remove, heat it using a small propane torch to break down the sealant.
When applying sealants, follow instructions on container. The sealants
listed below are recommended for use on Wacker equipment.

TYPE PART NO. -


( ) = Europe COLOR USAGE SIZE

Loctite 222 Purple Low strength, for locking threads smaller than 6 mm 73287 - 10 ml
Hernon 420 (1/4").
Omnifit 1150 (50M) Hand tool removable.
Temp. range, -54 to 149 ° C (-65 to 300 ° F)

Hernon 423 Blue Medium strength, for locking threads larger than 29311 - .5 ml
Omnifit 1350 (100M) 6 mm (1/4"). 17380 - 50 ml
Hand tool removable.
Temp. range, -54 to 149 ° C (-65 to 300 ° F)

Loctite 271/277 Red High strength, for all threads up to 25 mm (1”). 29312 - .5 ml
Hernon 427 Heat parts before disassembly. 26685 - 10 ml
Omnifit 1550 (220M) Temp. range, -54 to 149 ° C (-65 to 300 ° F) 73285 - 50 ml

Loctite 290 Green Medium to high strength, for locking preassembled 28824 - .5 ml
Hernon 431 threads and for sealing weld porosity (wicking). 25316 - 10 ml
Omnifit 1710 (230LL) Gaps up to 0.13 mm (0.005")
Temp. range, -54 to 149 ° C (-65 to 300 ° F)

Loctite 609 Green Medium strength retaining compound for slip or press 29314 - .5 ml
Hernon 822 fit of shafts, bearings, gears, pulleys, etc.
Omnifit 1730 (230L) Gaps up to 0.13 mm (0.005")
Temp. range, -54 to 149 ° C (-65 to 300 ° F)

Loctite 545 Brown Hydraulic sealant 79356 - 50 ml


Hernon 947 Temp. range, -54 to 149 ° C (-65 to 300 ° F)
Omnifit 1150 (50M)

Loctite 592 White Pipe sealant with Teflon for moderate pressures. 26695 - 6 ml
Hernon 920 Temp. range, -54 to 149 ° C (-65 to 300 ° F) 73289 - 50 ml
Omnifit 790

Loctite 515 Purple Form-in-place gasket for flexible joints. 70735 - 50 ml


Hernon 910 Fills gaps up to 1.3 mm (0.05")
Omnifit 10 Temp. range, -54 to 149 ° C (-65 to 300 ° F)

Loctite 496 Clear Instant adhesive for bonding rubber, metal and plas- 52676 - 1 oz.
Hernon 110 tics; general purpose.
Omnifit Sicomet 7000 For gaps up to 0.15 mm (0.006")
Read caution instructions before using.
Temp. range, -54 to 82 ° C (-65 to 180 ° F)
Threadlockers and Sealants
TYPE PART NO. -
( ) = Europe COLOR USAGE SIZE

Loctite Primer T Aerosol Fast curing primer for threadlocking, retaining and 2006124 -
Hernon Primer 10 Spray sealing compounds. Must be used with stainless 6 oz.
Omnifit VC Activator steel hardware. Recommended for use with gasket
sealants.
Torque Values
Torque Values

Metric Fasteners (DIN)

TORQUE VALUES (Based on Bolt Size and Hardness) WRENCH SIZE

8.8 10.9 12.9

Size ft.lb. Nm ft.lb. Nm ft.lb. Nm Inch Metric Inch Metric

M3 *11 1.2 *14 1.6 *19 2.1 7/32 5.5 - 2.5

M4 *26 2.9 *36 4.1 *43 4.9 9/32 7 - 3

M5 *53 6.0 6 8.5 7 10 5/16 8 - 4

M6 7 10 10 14 13 17 - 10 - 5

M8 18 25 26 35 30 41 1/2 13 - 6

M10 36 49 51 69 61 83 11/16 17 - 8

M12 63 86 88 120 107 145 3/4 19 - 10

M14 99 135 140 190 169 230 7/8 22 - 12

M16 155 210 217 295 262 355 15/16 24 - 14

M18 214 290 298 405 357 485 1-1/16 27 - 14

M20 302 410 427 580 508 690 1-1/4 30 - 17

1 ft.lb. = 1.357 Nm. * = in.lb. 1 Inch = 25.4 mm


Torque Values
Inch Fasteners (SAE)

Size ft.lb. Nm ft.lb. Nm ft.lb. Nm Inch Metric Inch Metric

No.4 *6 0.7 *14 1.0 *12 1.4 1/4 5.5 3/32 -

No.6 *12 1.4 *17 1.9 *21 2.4 5/16 8 7/64 -

No.8 *22 2.5 *31 3.5 *42 4.7 11/32 9 9/64 -

No.10 *32 3.6 *45 5.1 *60 6.8 3/8 - 5/32 -

1/4 6 8.1 9 12 12 16 7/16 - 3/32 -

5/16 13 18 19 26 24 33 1/2 13 1/4 -

3/8 23 31 33 45 43 58 9/16 - 5/16 -

7/16 37 50 52 71 69 94 5/8 16 3/8 -

1/2 57 77 80 109 105 142 3/4 19 3/8 -

9/16 82 111 115 156 158 214 13/16 - - -

5/8 112 152 159 216 195 265 15/16 24 1/2 -

3/4 200 271 282 383 353 479 1-1/8 - 5/8 -

1 ft.lb. = 1.357 Nm. * = in.lb. 1 Inch = 25.4 mm


Wacker Construction Equipment AG · Preußenstraße 41 · D-80809 München · Tel.: +49-(0)89-354 02 - 0 · Fax: +49 - (0)89-354 02-390
Wacker Corporation · P.O. Box 9007 · Menomonee Falls, WI 53052-9007 · Tel. : +1-(1)(262) 255-0500 · Fax: +1-(1)(262) 255-0550 · Tel. : (800) 770-0957
Wacker Asia Pacific Operations · Sunley Center, Unit 912, 9/F · 9 Wing Qin Street, Kwai Chung, N.T. · Hong Kong · Tel. + 852 2406 60 32 · Fax: + 852 2406 60 21